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Insttruction Manua
al
for
Electro--Hydraulic Steering Ge
ear
(RE & FE Series)
剾
Read and keep th
his Instruction Manual & Finished Plan.
FLUTEK, LTD.
Marine Machinery Facto
ory
HanJi 18 Gil 70, Bongsu-myeon n, Uiryeong-gun, Gyeongnam, Republic of Korea
a
(Tel : 82-55-570-5721, Fax : 82
2-55-574-5713)
Danger : indicates an imminently hazardous situation which, if not avoided, will result in
death, serious injury
i or serious accident.
Installatio
on, removal, piping and wiring shall be do
one by the certified
WARNING
person.
Make it suure that the power of the hydraulic powerr unit is turned off
and that the
th electric motor has completely stoppedd before starting
WARNING
installatio
on or removal. You must also check the sy
ystem pressure has
dropped to o zero.
Use the sppecified bolts and keep the specified tighttening torque when
you installl the product(part). Usage of unauthorizeed bolts, lack of
CAUTION
torque, orr excess of torque may create problems su uch as failure of
work, dammage and oil leakage.
Clean the threads
t and mounting surface completely y, otherwise you may
CAUTION experience e damages or oil leakage caused by insufffficient tightening
torque, bro
roken seal.
Make it su
ure that piping and wiring are correct and
d all the connection is
CAUTION tightened correctly before start operating, especiallly if it is the first
run. Otherrwise you may experience injury.
Keep yourr body off the product during the operatio
ons as it may become
CAUTION
hot, in ord
der to avoid a burn.
2.1.1 Tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5 Steering method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
e
6 Instructions for maintenance ........................................ 32
6.4 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of ram V-p 42
R..........................................
Fig.リユHYDRAULIC CYLINDER 60
ES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig.レユVALVE UNIT (RE SERIE 62
ES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE UNIT (FE SERIE 63
Fig.ロユFUNCTION OF OB VALV
VE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
OB VALVE (OB20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
OB VALVE (OB30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fig.15ユTORQUE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
REG-260/500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVO PUMP UNIT (R 79
Fig.19ユLINE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
PACKINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig.23ユASSEMBLY OF RAM V-P 85
FLUTEK-Kawasaki Electrica
al Pump Control (Continuous Control) Steering Gear is of the “Rapson
and piping, FLUTEK-Kawasaki axial piston pump and pump control unit.
The ram thrust produced by the pressure oil is transmitted to the tiller arm through the ram
pin and the roller bearingss and converted to the torque of the tiller keyed to the rudder stock
the repeat back unit, and when it coincides with the signal of the order rrudder angle, the
rudder stops.
the actual rudder angle is directly compared with the order rudder angle
e and the deviation
signal between order and actual rudder angles controls directly the tilting
g angle of the
hydraulic pump.
and the ship can keep herr heading correctly with a less steering order.
classification society is fixed to the rudder stock with the key. On the ffork typed openings of
the tiller, the hardened steel plates are bolted and they contact directlly with the roller
bearing of the ram. Acccording as the roller bearing rotates on this surrface, the linear
(1) The ram is made off carbon steel for mechanical structural use, and the hydraulic
(2) The ram pin is incorrporated into the center of the ram whose surfface has been finished
with high accuracyy, and the rotatory roller bearings (1121) are fittted into the upper and
lower parts of the ram pin and contact directly with the fork typed openings of the tiller
arm. The ram thrust is transmitted to the tiller through the ram p
pin.
The oilless metal iss fitted in the bore of the roller bearing and min
nimize the rotational
friction between th
he ram pin and the roller bearing.
aulic cylinders that move the two (or one) sets of ram are securely
(3) Four (or two) hydra
installed on the be
ed plate of the hull.
The hydraulic pump unit and the electric motor are installed on th
he hydraulic cylinders.
Inside of the each hydraulic cylinder, neck bushing (1205) is provvided, supports the ram
The oil tank is made off cast iron and mounted on the hydraulic cylinde
er.
Inside of the tank, the hydraulic pump, linkage necessary for tilting th
he pump cylinder and
(1) Function
Starting up one pu
ump only provided that two or more pumps are installed and also
piping connection is
i ready for parallel running of the pumps, delivvered pressure oil from
the running pump will not actuate ram, but merely drive the idle pumps in their reverse
direction.
The oil block valve is a provision for preventing reverse driving off the idle pump.
The oil block valve consists mainly of main spool, spring and valvve casing having ports
ram.
end of main spool and valve is in the position where ports AV and
d BV are by-passed
Control (Continuou
us Control) Steering Gear :
Ꮿ At the operation of
o rudder limiter, steering gear can be instantan
neously stopped by
Ᏸ At the failure of co
ontrol source, steering gear can be automatically stopped by being
“OFF” condition.
400 kgf/cm2}, compact and light, and shows high volumetric and
pressure of 39.2 MPa {4
The pump consists mainly of the cylinder (151) fitted in the cylinder ccasing (202), the seven
piston sub (NO. 123-pisston, NO. 121-connecting rod, etc.) being in recciprocating motion in
nder, the driving shaft sub-group which transmits power to the pump,
seven bores of the cylin
pport the driving shaft, the bearing casing (201)), the front cover
the bearings which sup
the spherical constructiion, self-centering can be obtained when the cyylinder is rotated.
The driving shaft (101) is supported by the bearing casing (201) throu
ugh the roller bearing
02) together with the cylinder (151), therefore, can be tilted around
The cylinder casing (20
Rotating motion of the driving shaft (101) actuated by an electric mottor is transmitted to
In the case the cylinderr (151) is located in the oblique position againsst the driving shaft
centre, the piston (123) reciprocates in the cylinder bore relatively to the cylinder.
cover (253). The valve plate (171) and the cylinder (151) are in optim
mum hydraulic balance
The driving shaft (101) of the pump is driven by the electric motor thrrough the flexible
coupling.
Rotating motion of the shaft is thereafter transmitted to the cylinder tthrough the piston sub
as described in foregoin
ng sub-section.
illustrated.
Middle and bottom of the right figures are the sections perpendicular to the left figure, and
In the case that the tiltting angle of the cylinder is equal to zero, i.e. th
he axis of the cylinder
d the cylinder bore with pump rotation will not occur, no oil will
between the piston and
consequently delivered. No delivery from the pump with its rotation as described above is
called as neutral.
In the case that the cyllinder is tilted around its tilting axis as shown in
n the bottom figure,
the pistons below X-Y liine are going to withdraw from the bottom of tthe cylinder bore with
above X-Y line are going to approach to the bottom of the cylinder bo
ore and discharge oil
position and reaches itss maximum value at the tilting angle of 27 degrees (the maximum
t cylinder bore will take place, accordingly the pistons below X-Y
the pistons relative to the
uch being the case, direction of flow can be changed without altering
through the port “a”. Su
Relation of direction be
etween oil flow and tilt of the cylinder is shown in the table.
The valve plate (171) in Fig. 8 having two ports “a” & “b” in Fig. 9 is of importance for
The signal of order rudder angle is compared with the feed-back signa
al of actual rudder
angle at the steering sttand and its deviation signal is transformed into
o the pump control
applied to the hydraulicc cylinder, and the tiller will be rotated through the ram and the ram
pin.
pump control signal beccause the electric signal of pump tilting angle is feed-backed to the
In proportion as the acttual rudder angle nears to the order angle, the
e hydraulic pump
returns to neutral position due to the reverse rotation of torque motorr and the tiller stops
when the actual rudderr angle coincides with order angle and oil is nott discharged from the
2.3.2 Construction :
This box is supplied by the autopilot manufacturer in order to transform the deviation
ering stand into the pump control signal and drive the torque motor.
signal from the stee
This unit consists off hydraulic regulator, torque motor and pump tiilting angle indicator
The pump control siignal from control box drives the torque motor and the hydraulic
Operation of reg
gulator is explained by referring to Fig.12.
movement is con
nverted to the stroke of spool.
sleeve.
e oil from servo pump is lead into the chamber A (oil passage from
figure), pressure
“c”. Accordingly the servo piston (403) moves rightward and sttops at the position
03) tilts the pump in the same direction and by the same angle in
Servo piston (40
figure), pressure
e oil is lead into both chamber A and B. As presssure receiving area of
the drain opens to chamber B and the oil passage from “a” to ““b” is closed.
Note : Neutral position has been adjusted and set the adjusting pin (302) before
hydraulic regulattor.
LVDT is provided
d in order to detect the movement of pilot spoo
ol and feed-back the
electric signal off the pump tilting angle to the control box.
LVDT consists off the case (2) with coil (9), the spindle (11) and
d core (10) connected
Servo Pump Unit is provided in order to supply the pressure oil to hydraulic regulator
pressure. Adjusting pressure is 1.8 - 2.0 MPa {18-20kgf/cm2} and set before delivery.
The filter consists off the filter head (1) with an visual indicator (8) & by pass valve (relief
(5.1) Indicator
During the filtrattion, the filtering surface is contaminated by the accumulated dirt in
pressure) before
ehand.
When the indicator ring (red) is floated up to the white level in the column (highest
However it will be
b desirable to clean when the ring reaches the
e middle position in
condition (highest position), the element (5) may be damaged since the pressure on
ncreased due to the less of allowable flow. The by-pass valve (11) is
element (5) is in
provided in orde
er to prevent the damage of hydraulic equipmen
nts, and the valve is
Rudder angle limiterr is provided in order to stop the movement of steering gear
instantaneously by cancelling
c the electric signal to torque motor an
nd de-energizing the
by any reason over than the max. working angle (35 degrees on e
each side).
the movement of ra
am.
then installed on the bed plate of the hull. The installation of the importa
ant components such
bed plate.
For smooth operation and correct rudder angle, the installation should be
e strictly carried out in
accordance with the relative positions and dimensions of each parts. Forr easy installation, the
hipped after bending and cleaning (by pickling, flushing and corrosion
The hydraulic pipes are sh
preventing) of pipes are carried out and each flange is applied with blind
d plugs at our works.
etc.
Until the basin trial of the steering gear, cover the surface of the ram witth cloths for preventing
4.1 Preparation :
4.1.1 Wiring :
temperature is limite
ed to -20
~ 80 due to oil seal, 0-ring etc. Further, as the
150
100
75 Optimum
50 working range
40
30
25
20
15
10
9 Low viscosity limit
8
7
6
°C -30 -20 -1
10 0 10 20 30 40 50 60 70 80 90 1
100 110
°F -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230
The hydraulic oil havving the following properties has widely used fo
for the steering gear
Caution :
1. The oil must be dealt with carefully not to allow dust and other impurities to mix.
3. The working oil for the use especially in cold regions shall be a
asked to the oil maker
When working oil is filled in hydraulic system, a filter of 200 mesh or over should be
͛ Fill the hydraulic cyylinder with oil little by little through the oil fille
er at the upper part of
hydraulic cylinder. In this case, air vent valve and cylinder stop vallve should be
thoroughly opened.
level gauge.
Since the roller bearing and each joint portion of the steering gear a
are provided with
͛ Slightly apply greasse for rust prevention to other machined surfacces (especially to the
hydraulic pump and electric motor, oil leak from the oil seal, wear of the coupling etc.
Correct centering sh
hould be checked in the following manners.
coupling of the pu
ump.
pointer to the point near the outer face of the coupling of the pu
ump.
The permissible to
olerances of the parallel error and inclination error shall be adjusted
the packings.
4.2 Adjustment :
After the preparation off each part has been finished, operation and ad
djustment will take
ace carefully, open the stop valve and close the air vent valve.
Clean each sliding surfa
In the first place dissconnect the control box from electrical power.
After confirmation of
o the pump tilting angle being roughly in neutrral by means of the
g direction of hydraulic pump and check for oil leakage from the front
Confirm the rotating
The servo pressure supplying to the hydraulic regulator should be adjusted to 1.8 ~ 2.0
If the adjusted presssure should be the different value from the abo
ove at a daily check,
adjust it according to
t the following procedure.
Remove the cap nutt (3-10), loosen the lock nut (3-6), and adjust tthe pressure by
Turn the screw clockkwise, and the pressure rises, and vice versa.
Open the air vent plug, and turn the pump control knob to the righ
ht and left alternately
1. Stroke fully the tiilting lever (Fig.3-1681) together with the pump
p to the direction of
hydraulic regulattor.
2. After installing the power lock (Fig.3-1741) at the end of servo piston (Fig.13-403),
Then connect the piston and the lever by tightening the powerr lock (Tightening
n Fig.3).
torque is listed in
1. Disconnect the co
ontrol box from electric power. Push the manua
al button of the
solenoid valve forr unloading device and lock it by means of lock nut.
spanner (about 30
00 mm), and turn to the right or left slightly to
o find where the ram
stops. Adjust it in order that the ram movement is less than abo
out 0.5 degrees/min.
to zero position.
adjusting pin.
1. Insert the rotor (Fig.15-12 and -13) into the rotor shaft (Fig.13--103).
2. Install the frame (Fig.15-1) without the name plate (Fig.15-5) sso that its receptacle
(Fig.15-6) becom
mes in the direction of port or starboard side.
3. Insert the clamp element (Fig.15-2) and flange (Fig.15-10) into the rotor. (Direction of
rotor is referred to
o Fig.13.)
ever (Fig.15-3) on the flange and lock it with flange by means of bolt
4. Put the stopper le
(Fig.15-4).
5. Fit the name platte and knob. (The direction is shown in Fig.13.))
pump is tilted after starting, its abnormal noises prove that a greatt amount of air is still
solenoid control valvve and lock it by lock nut and operate the steerring gear slowly with
movement begins.
necessary.
e opened, the air that has tried to expel will be sucked in again.
If it will be
2. Before exp
pelling the air, don't run the hydraulic pump forr hours.
(4) Adjustment of ru
udder angle
This adjustment serrves to limit the maximum tilting angle during tthe local steering.
Note : In this adjusttment, prevent the stopper lever (Fig. 15-3) fro
om striking this bolt
(Fig. 15-7) du
uring the normal steering without fail.
lever.
Set the limit switch position of the rudder angle limiter at 36.2degrees͟ Confirm that the
degrees on eithe
er side to 30 degrees on the way to 35 degreess on the other side in
͛ Correct adjustm
ment has been finished before delivery from ourr works.
on either side to
o 15 degrees on the other side in 60seconds witth the vessel running
ahead at half speed or 7 knots (or 8 knots), whichever is greatter. One pump is used
in emergency ste
eering.
The adjusting presssure has been set at the adjusting pressure shown in PARTICULARS
However, it is nece
essary to confirm the operation on board togeth
her with the pressure
test of the hydraulic pipes, gaskets etc., whose procedures are ass follows :
(1) Preparation :
(Local steering).
͛ Disconnect the co
ontrol box from electrical power.
͛ Push the manual button of the solenoid control valve and lock it by means of lock
nut.
Depending on the
e safety valve subject to confirmation, the hydrraulic pump and the
͛ Start the electric motor and hydraulic pump and operate the ste
eering gear by the
nob.
pump control kn
͛ When the rudderr angle is over 35 degrees, move the rudder slo
owly.
pump tilting angle. Under this condition, confirm the adjusting pre
essure of the safety
pressure is marked with red on the dial plate of the pressure gaug
ge.)
͛ The operation of th
he safety valve shall not exceed 30 seconds at a time because the
͛ Remove the safety valve cap nut (3-10) and loosen the lock nut (3-6).
Pressure will rise if sccrew is turned to right and pressure will drop iff turned to left.
After finish of the tesst, put the stop valve, isolating valve, solenoid ccontrol valve, pump
and changing :
For details, refer to the Instruction Manual of the autopilot maker beca
ause the contents are
Also changing-over of th
he hydraulic pump can be done by the remote control of electric
motor.
Precautions :
In failure of the control system in the wheelhouse (bridge) or during the adjustment
(1) Preparation
stop automatically.
Precautions :
plate.
3. Reduce the ship's speed to half of the max. service speed or 7 kknots (or 8 knots)
eral hydraulic oil or equivalent, and keep the working oil fully
Apply good grade mine
Any air in the hydraulicc system will produce abnormal noises from the
e hydraulic pump and
cause not only unstable rudder angle but also other troubles. In case
e of replenishing the
instruction plate.
Never open the valves during the steering gear is operated. If not, it will cause the
failure of steering.
͛ Safety valve :
Properly apply the lubrricant on the ram surfaces and sliding levers.
Starting up under a big eccentricity will have the possibility of caussing the excessive
Long-time operation off hydraulic pump at zero tilting angle at anchorr should be avoided as
far as possible.
If unavoidable, it should be limited within 24 hours, because this will be undesirable for the
conditions of hydraulicc pump and steering gear, tightness of bolts, oill leakage etc.
Period Che
eck items Period Check items
erating condition
B-1 General ope (1) Safetyy valve
A) Daily checks :
n oil tank :
A-1 Oil quantity in
͛ Check the oil level in oil tank is within the visible range of th
he oil level gauge. If
e the cause, repair if necessary and refill oil tank with new clean oil.
not, examine
exceeds 80, stop the hydraulic pump and examine the ccause.
comparing with
w the normal data. If it is abnormally high, e
examine the cause.
͛ Check its oriigin in the steering gear and examine the cause
e.
͛ Check for oill leakage from the oil tank, hydraulic cylinder, vvalves and pipe joints.
͛ Check the te
emperature of torque motor, by comparing with
h the normal data.
Normally tem
mperature will be within 30 plus room temperrature. If it exceeds
B) Weekly checks :
necessary.
͛ Lubricate the
e ram surface, tiller hardened steel plate, rollerr bearing and levers.
of grease.
C) Monthly checks :
͛ Check the va
alves are securely closed.
͛ Check the va
alves are opened or closed correctly in accorda
ance with the
instruction plate.
p Tighten them hard up by means of lock n
nuts not to be
͛ Check for oill leakage from the drain inspection ports provid
ded at the foot of
torque moto
or. Renew oil seal (Fig.13-109), if necessary.
D) Quarterly checks :
If loosen, tig
ghten them evenly and hard up.
D-2 Turnbuckle :
͛ Check the nuts and lock washers for turnbuckle are tighten
ned hard up.
D-3 Coupling :
* Exchange th
he grease in the chain coupling.
First exchang
ge : Within one month
Second excha
ange or more : Every three months
͛ Confirm thatt the alarm is given by pushing up the test bar of float switch
mounted on
n the oil tank.
͛ Check the clogging condition of filter by means of visual indicator. Wash the filter
element, if necessary
n (Refer to item 6.5).
E) Semi-yearly checkks :
͛ Check for an
ny abnormal wear.
F) Yearly checks :
͛ Clean thorou
ughly.
͛ Make a perio
odical property inspection of the working oil.
͛ Check the oil levvel in oil tank is within the range of the oil leve
el gauge.
plate.
͛ Check the lubriccating condition of each sliding part. Check for any rust.
non-follow up steering
s mode in no-load condition.
͛ Check the safetyy valves are set at adjusting pressure. (The adjjusting pressure is
͛ Check there is no
n large difference between the above data and
d the trial data.
(3) Coupling :
͛ Check the errors of centering are within the standard value byy measuring the
permissible valu
ue.
͛ The permissible
e value of clearance : 0.5mm
pins.
͛ Replacement off packing is not required when there is no oil leakage from the
͛ If oil leakage is observed from the drain inspection ports proviided at the foot of
age is not observed, it is desirable to renew oil seal about every five
͛ Even if oil leaka
years.
as it is by tighte
ening additionally.
(11) Cylinder-bottom
m packing : (Fig. 2)
If oil leakage iss not stopped, tighten it again by touching the rram to the plug and
Caution :
This packing hass been installed inside of the hydraulic cylinder. Therefore the packing
cannot be renew
wed unless the ram is drawn out.
found faulty, re
epair or replace the electric motor.
* It is desirable to
o renew the bearing of the electric motor for se
ervo pump about every
three years.
analysis.
͛ Clean thoroughlly the interior of the oil tank when the working oil is renewed or
bearings.
As it is used long perriod the working oil will be mixed with foreign m
matters, deteriorated
If the result exceeds the renewal standard, renew the working oil.
n of foreign matter ?
c. Isn't there any sign
d. Isn't it emulsified ?
During the replacementt work of the packing, care should be taken to avoid damaging the
V-packings can be drrawn out by making use of the friction with the ram.
b. Move the ram slowly by local steering. (The packing can be drrawn out little by little
If packing canno
ot be drawn out by above work, prepare a suita
able tool and draw out
the adapter and packing. (The screw holes has been machined
d on the female
c. Wind the new paccking to the ram. At the moment, confirm that the section is
correctly met. (If the packing is hard, make it soft by hand rub
bbing.)
e. Follow the same manner subsequent to the second one. At the moment, the
together.
g. Operate the steerring gear by the pump control knob and adjustt the packing gland
Cautions :
sealing.
When the indicator (8) of the filter shows the clogging condition (red ind
dicator ring is floated
up to the white level in the column), the line filter will be dismantled and
d the filter element (5)
is changed to new one or cleaned in the following procedures. It will be desirable to clean
c) Grab the hexagon plug on bottom of filter case (2) with large monkeyy spanner (about 300
Caution :
er case (2), hold the filter case and filter element respectively with
d) After loosening the filte
hands, and pull out the filter element downward with twisting slightly.
e) Wash the filter elementt (5) by shaking in the washing oil and clean itss surface by using a
Caution :
1) Check the o-ring (3) & back-up ring (4) before assembly, which are inserted inside
of filter head (1), for prevention of oil leak between filter case(2)) & filter head(1).
2) Tightening torque
e of filter case (2) : 160 Nȡm (16 kgȡP
The hydraulic pump willl be dismantled and checked in the following prrocedures.
However, special attentiion and skill in dismantling and assembling of tthe pump are required,
so it is recommendable that the work is performed by the specialist, iff possible (Exploded
a. Tools necessary fo
or dismantling and assembling of the pump (ba
ar spanner M4 ~ M20,
a. Discharge oil conttained in the oil tank, disconnect the hydraulic regulator, hydraulic
tank and lift the pump by the chain block. Place the pump on a proper wooden piece.
Caution :
Disassemble at a clean
c place.
Caution :
Caution :
1) Care should be taken not to lose the cylinder spring (165) beccause it is come out
Caution :
Caution :
larger according to
o the size of pump.
Caution :
1) Remove the covver by using the drawing bolt holes without gra
aver and driver.
is damaged, re
eplace at assembly.
Caution :
1) Check that therre is nothing wrong with the roller bearing (104
4) and the tapered
111). If nothing, don't pull out them and leave inside of the bearing
roller bearing (1
casing (201).
2) Don't remove the piston, connecting rod etc. from the driving shaft (101).
Ꮿ Worn componentts :
Care should be ta
aken especially to the wears between the pisto
on sub and the cylinder,
connecting rod and the set ring, the center rod and the cylinderr. If there is no
Ᏹ Bearing :
Caution :
Ꮿ General cautions :
assembly.
If waste cloth is used, take care that fiber scraps will never rem
main on the cleaned
parts.
Tightening Torque
Bolt size
Material Item Unit
M4 M5 M6 M8 M10 M12 M16 M18 M20
kgf·cm
m 35 70 120 300 580 1,000 2,400 3,400 4,400
SCM435 Torque
N·m 3.4 6.9 11.8 29.4 56.9 97.1 235.4 333. 431.5
Ᏸ Cautionary Instructio
ons in Assembly :
g to the periphery
the liquid packing
c. When inserting th
he thrust pad
inserted.
f. After the assembly is over, rotate the driving shaft (101) by han
nd and ensure there
is no abnormalityy.
Then, install the pump inside of the oil tank and put it to the orriginal condition.
b. Remove the stop ring for ram pin with a pliers and take off the upper and lower roller
bearings.
Caution :
The lower roller beariing will drop if the stop ring is removed, so safe
ety is especially given
to the work.
e. Jack up the ram pin from the lower part and pull out it completely up
pwards.
f. Carefully and slowly turn the tiller and rudder plate (rudder stock) by means of a winch at
Caution :
the key, jack up only the tiller and turn it up to the 90degrees positiion.
pintle portion.
At the moment, screw the set screw for ram pin and bolts for guide b
bracket without fail.
(1) The Steering Gear Sysstem is considered to be classified into the auto
o-pilot system
in the wheel-house (brridge), the continuous control system such as tthe control box,
the pump control unit etc, that controls the pump tilting angle in the steering gear room
with the above order received, and the steering gear, such as the ram
m, the cylinders,
separating the auto-pillot system and the continuous control system ffrom the steering gear
en for failure in any power unit, stop the power unit concerned (and
(2) When an alarm is give
be carried out.
continuous control systtem. Then proper remedies should be taken byy referring to the
(5) Take smooth procedurres in the transportation and disassembly of heavy weights, and
Chart.
e:
a. External oil leakage
͛ Check for oil leakkage from the ram V-packing and connections.
͛ Disconnect the co
oupling with the hydraulic pump and investigate
e which is in trouble,
͛ Check that the sttop valve and isolating valve are opened or clossed as indicated on
͛ Check for abnormal noise of running pump or the opening of the suction valve.
The time of rudder turrning speed is measured when the rudder move
es from 35 degrees on
requirements).
Check that the stop valve and isolating valve are opened or closed as indicated on the
instruction plate.
Check that the adjussting pressure of the safety valve is not reduced
d.
Air contained in the hydraulic circuits will cause the delayed respon
nse.
e has roughly been set up depending upon the type of steering gears.
The tightening value
c. Excessive clearance of
o the pin of pump control unit :
If the clearance of th
he pin of pump control unit becomes abnormallly great,
he pin for repeat back unit becomes abnormallyy great, actual rudder
If the clearance of th
becomes abnormallyy great, the steering gear will not stand still.
circuits.
if necessary.
e in all cylinders :
(6) Abnormal pressure rise
the pump and fully exxpel the air. (Operate the steering gear at leastt every 24 hours.)
When the stop valvess are provided on the hydraulic cylinders, closin
ng of the valve will be
It is therefore necessary to disassemble the OB valve for detailed ccheck. Special care
check, take necessary measures, such as lapping the spool, facing up the seat of the
pumps.
temperature. If this difference is abnormally large, stop the pump iimmediately for check.
approximately at the ro
oom temperature plus 30.
condition of the bearing. Disassemble the pump for check and repa
air.
Foreign matters in th
he working oil may cause troubles, although it is not so often the
case.
͛ In this case, burning of the electric motor, failure of the electric sou
urce and starter, and
SOCKET BOLT
(2911)
SHEET PACKING
MANIFOLD (2909)
(2907)
EMERGENCY
NORMAL
SOCKET BOLT
(2911)
SOLENOID VALVE RELIEF VALVE
(2904) (2950)
TILLER
RUDDER STOCK
UP
SPRING (521)
POPPET (2-2)
SPRING SEAT (531) BUSHING (2-1)
O-RING (561)
B
RO PLUG (551)
BC T
(AC)
SOCKET BOLT O-RING (163)
(171)
SECTION B-B
SEAT (541)
POPPET (511)
SPRING (521)
Y X
AV BV
O-RING
(164) O-RING
SPRING
(161) O-RING (561) HYDRAULIC CIRCUIT
(321)
SPOOL (301)
SPRING SEAT
(331) RO PLUG (551)
SECTION A-A
T
SAFETY VA
SECTION C-C
PLUG (351)
O-RING (162)
SPRING (321) SPRING (322)
SPOOL (301)
WASHER
CASING (101) (331) POPPET
(311)
SECTION A-A
LOCK NUT (3-6)
CAP SCREW (3-10)
ADJUSTING PLUG AC T BC
(3-1) ADJUSTING SCREW (3-2)
SAFETY VALVE
B (600) O-RING (3-8) COPPER PACKING (3-26)
RD20C-10-2/
SPRING SEAT (3-3)
Tightening torque
167N.m (1700kgf·cm) C-RING (3-4)
O-RING (3-5) NAME PLATE
SPRING (4) (SAFETY VALVE) (992) Y X
STICHING RING (6) AV BV
CASING (1)
NAME PLATE (TYPE) HYDRAULIC CIRCUIT
(991) BACK-UP RING (8)
UP
O-RING (7)
A A SPRING SEAT (2-3)
POPPET (2-2) Tightening Torque
BUSHING (2-1)
NO. SIZE TIGHTENING TORQUE
171 M16 235 N.m (2400 kgf·cm)
Y AV BV X BC T 271 M12 69 N.m (700 kgf·cm)
(AC) 551 M27 176 N.m (1800 kgf·cm)
B O-RING (163) 600 - 294 N.m (3000 kgf·cm)
SOCKET BOLT SOCKET BOLT
O-RING O-RING (171) (172)
(161) (164)
SECTION B-B : Setting pressure of relief valve
T
SAFETY VA
SECTION C-C
PLUG (351)
O-RING (162)
SPRING (321) SPRING (322)
SPOOL (301)
WASHER
CASING (101) (331) POPPET
(311)
SECTION A-A
LOCK NUT (3-6)
CAP SCREW (3-10)
ADJUSTING PLUG AC T BC
(3-1) ADJUSTING SCREW (3-2)
SAFETY VALVE
B (600) O-RING (3-8) COPPER PACKING (3-26)
RD30C-10-2/
SPRING SEAT (3-3)
Tightening torque
196N.m (2000kgf·cm) C-RING (3-4)
O-RING (3-5) NAME PLATE
SPRING (4) (SAFETY VALVE) (992) Y X
STICHING RING (6) AV BV
CASING (1)
NAME PLATE (TYPE) HYDRAULIC CIRCUIT
(991) BACK-UP RING (8)
UP
O-RING (7)
A A SPRING SEAT (2-3)
POPPET (2-2) Tightening Torque
BUSHING (2-1)
NO. SIZE TIGHTENING TORQUE
171 M16 235 N.m (2400 kgf·cm)
Y AV BV X BC T 271 M12 69 N.m (700 kgf·cm)
(AC) 551 M27 176 N.m (1800 kgf·cm)
B SOCKET BOLT O-RING (163) 600 - 294 N.m (3000 kgf·cm)
O-RING O-RING (171)
(161) (164)
SECTION B-B : Setting pressure of relief valve
SPOOL (23)
P T
A B
"N" "E"
DRIVE SHAFT
CASING
A PORT
TILTING
DIRECTION
RIGHT
B PORT
NEUTRAL
a DELIVERY PORT
TILTED
b SUCTION PORT
DELIVERY PORT A B
SUCTION PORT B A
RUDDER DEVIATION
AC100V-60Hz
CONTROL BOX CONTROL BOX
NO.2 MOTOR STARTER NO.2 MAIN MOTOR NO.1 MAIN MOTOR NO.1 MOTOR STARTER
TRANSFORMER TRANSFORMER
REG090 54
REG260 71
REG500 89
CABLE COLOR
B : BLACK
BU : BLUE
G : GREEN
R : RED
W : WHITE
Y : YELLOW
SOCKET BOLT(4)
STOPPER
LEVER (3)
BOX TYPE
RECEPTACLE (6)
TORQUE MOTOR
REGULATOR
KNOB
OIL TANK
O-RING (13)
SEAL WASHER(6)
Outlet Inlet
OU T
IN
O-SEAL MALE ELBOW (2605)
COVER (1)
ELECTRIC MOTOR SHAFT PUMP SHAFT SERVO
MOTOR PUMP
BUSH BLOCK (12)
Outlet Inlet
OUT
IN
O-SEAL MALE ELBOW (2605)
COVER (1)
ELECTRIC MOTOR SHAFT PUMP SHAFT SERVO
MOTOR PUMP
BUSH BLOCK (12)
AIR
RELEASE PIPE
OIL TANK
OPEN CLOSE
TO OIL TANK
FILLING PLUG
HIGH PRESSURE
RAM
DETAIL "A"
Caution
- Open the air vent valve attached on the cylinder where the ram is drawn
(high pressure. Side) and release the air.
ELEC. MOTOR
OIL TANK
GUIDE BAR
Steering gear Does oil GOOD Is electric GOOD Are valves GOOD Does abnormal GOOD Are there any GOOD Are safety GOOD Is air releasing GOOD Is hydraulic GOOD Does oil block GOOD Check hydraulic
does not work leak? motor running? operated perssure rise in obstacles around valves adjusted valve closed? pump tilted? valve change pump
correctly? all cylinders? tiller and ram? correctly? over on-load?
NO GOOD NO GOOD
NO GOOD NO GOOD NO GOOD NO GOOD NO GOOD NO GOOD NO GOOD
Tighten packing Operate valves Check spool Remove it Re-adjust Close it Is solenoid- GOOD Is selector GOOD Is filter GOOD Is orifice or
additional or according to operation of safety valve controlled valve valve stuck? clogged? pilot line
replace packing instruction plate OB valve (Refer to 4.2.10) changed-over? clogged?
NO GOOD NO GOOD
Is solenoid GOOD Is selector GOOD Is filter
NO GOOD
electric source valve stuck? clogged?
Check electric Check electric ON?
source motor
NO GOOD NO GOOD NO GOOD
NO GOOD
NO GOOD NO GOOD NO GOOD
Check Lapping of Replace
control box spool solenoid
Rudder turning Does oil GOOD Are valves GOOD Are there any GOOD Are Safety GOOD Is air releasing GOOD Is pump max. GOOD
speed is slow leak? operated obstacles around valves adjusted valve closed? tilting angle
correctly? tiller and ram? correctly? correct?
NO GOOD
Steering gear Is air contained GOOD Are there any GOOD Is ram packing GOOD Is pump tilting GOOD Check clearance Adjust control box Is servo pressure GOOD Does pump GOOD Does servo piston GOOD Check
does not work in hydraulic obstacles around over tightened? angle unstable? between rudder (Adjust pump max. 1.8-2.0 MPa control unit of hydraulic hydraulic
smoothly circuit? tiller and ram? stock and bearing tilting angle) (18-20 kgf/cm²) move? regulator move? pump
Check
Adjust it Check it or Check it or Check it or control box
Check them or
at 2°-5° replace part replace part replace part
refit them
Abnormal noises Do nises occur NO Do noises occur GOOD Do noises occur GOOD Do abnormal GOOD Investigate Is relief valve GOOD Is line filter GOOD Is servo pump GOOD Check
while ship is whenever rudder from ram from rudder noises from abnormal noises adjusted clogged? abnormal? servo piping
under voyage is worked? packing? carrier? hydraulic pump? source and check it correctly?
Release air Loosen ram Check lubricationg Check hydraulic Re-adjust Clean filter Check servo pump
packing a little condition or consult pump relief valve element
with shipbuilder